DesertTortoise
Well-known member
- Joined
- Jun 6, 2014
- Messages
- 1,189
In the last report from the KHDRC you will recall the non-standard switch and associated wiring had some clearance problems with the rear axle. Trying to wiggle the wires and switch around while fitting the lower half of the vacuum body resulted in the switch breaking.
Fortunately the center bought two such switches and staff reassessed the method of attaching wires to the switch. The switch has screws at each post intended to secure a spade connector, and this was how the center initially fitted wires to this switch. However, due to limited clearance, the center instead chose to delete the screws and twist and solder wires directly to the posts. In addition it was thought that having the wires exit the switch to the side would provide enough clearance from the axle to allow assembly without a lot of movement of wires and wiggling of the switch.
You can see in the images how the wires are now attached to the switch. Doing so was made difficult in two ways. The guage of wire used is about the same size as the threaded holes in the posts, making it very tough to thread the wire through the holes without the threads catching strands. Second, one post has to have two wires attached to the same post, the yellow wire and the jumper wire that permits the switch to function as a speed control. Holes had to be hand filed to create sufficient clearance for the wires.
Unfortunately the center's Director has limited experience with the assembly of electrical components and neglected to notice the tab in the hole or the notch in the threaded mount on the switch which orients the switch in the body. As a result the switch and the wires are oriented 180 degrees from what the Director intended and wire clearance with one rear wheel became a problem. Had the wires exited in the opposite direction the installation would have been very nice. As a stop gap, a plastic shield was constructed from material salvaged from a food container lid ( ! ) but the center intends to procure a new switch and pay closer attention to detail.
For now, sufficient clearance was found to allow the vacuum to be reassembled and tested. The freshly rebuilt motor is very quiet, however the kludged together lid hinge does not provide sufficient stability to achieve a good seal. More air is sucked through leaks than through a hose. Further development is needed, but for now the vacuum is assembled and runs fine.
An image of a successful ground run at low speed is depicted with a member of center restoration staff looking on in the background.
The Avocado Bomber finally gave the staff a reason to smile.
Fortunately the center bought two such switches and staff reassessed the method of attaching wires to the switch. The switch has screws at each post intended to secure a spade connector, and this was how the center initially fitted wires to this switch. However, due to limited clearance, the center instead chose to delete the screws and twist and solder wires directly to the posts. In addition it was thought that having the wires exit the switch to the side would provide enough clearance from the axle to allow assembly without a lot of movement of wires and wiggling of the switch.
You can see in the images how the wires are now attached to the switch. Doing so was made difficult in two ways. The guage of wire used is about the same size as the threaded holes in the posts, making it very tough to thread the wire through the holes without the threads catching strands. Second, one post has to have two wires attached to the same post, the yellow wire and the jumper wire that permits the switch to function as a speed control. Holes had to be hand filed to create sufficient clearance for the wires.
Unfortunately the center's Director has limited experience with the assembly of electrical components and neglected to notice the tab in the hole or the notch in the threaded mount on the switch which orients the switch in the body. As a result the switch and the wires are oriented 180 degrees from what the Director intended and wire clearance with one rear wheel became a problem. Had the wires exited in the opposite direction the installation would have been very nice. As a stop gap, a plastic shield was constructed from material salvaged from a food container lid ( ! ) but the center intends to procure a new switch and pay closer attention to detail.
For now, sufficient clearance was found to allow the vacuum to be reassembled and tested. The freshly rebuilt motor is very quiet, however the kludged together lid hinge does not provide sufficient stability to achieve a good seal. More air is sucked through leaks than through a hose. Further development is needed, but for now the vacuum is assembled and runs fine.
An image of a successful ground run at low speed is depicted with a member of center restoration staff looking on in the background.
The Avocado Bomber finally gave the staff a reason to smile.
